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I've been following this thread. In another world, I have a 66 GMC bus (4107 Buffalo, for those who care) that I am converting to an RV. There's a large news group supporting this acrtivity and these people have to deal with rust in a big way (sometimes 35-40' of it). Just about the best product these guys have found is something called Rust Grip. It is a polyurethane type product designed to penetrate and molecularly seal up rust. You first remove all the scale and loose rust you can, then paint or spray Rust Grip on. It penetrates right to the metal and really does seal the surface. I'm convinced that it works, what convinces me is that this stuff is about the nastiest stuff to work with I've ever seen. Cyanoacrylate (super glue) wouldn't be any worse to use. It penetrates anything, any crack, any seam, clothes, skin, any porous surface, and cannot be removed. Once it's dry, it sticks things together just about like super glue would. If you open a gallon can and then just put the lid back on without cleaning the can, you'll never get the lid off again. Some guys have cut the can open to use what's left. Anything you are going to apply on top of it, bondo, primer, paint, etc. must be done within two days, or nothing will stick to it. It is impervious. If you spray and don't thouroughly clean up, throw the sprayer away. It must be shipped as a hazardous material. Not allowed on planes. Despite all the above, it cures from the moisture in the air and is non toxic. Here's the URL: http://www.rustgrip.com/index1.htm In my opinion, it blows away any other product I've ever seen. Not cheap, though. Jim Showker ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ List info at http://www.vwtype3.org/list | mailto:gregm@vwtype3.org ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~